Omron SYSMAC C20K, SYSMAC C40K, SYSMAC C60K, SYSMAC C28K Operation Manual
Cat. No. W146-E1-5
Programmable Controllers
SYSMAC
C20K/C28K/C40K/C60K
K-type Programmable Controllers
OPERATION MANUAL
Revised July 1999
iv
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v
Notice:
OMRON products are manufactured for use according to proper procedures by a qualified operator
and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Always heed
the information provided with them. Failure to heed precautions can result in injury to people or damage to property.
DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Caution Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury, or property damage.
OMRON Product References
All OMRON products are capitalized in this manual. The word “Unit” is also capitalized when it refers
to an OMRON product, regardless of whether or not it appears in the proper name of the product.
The abbreviation “Ch,” which appears in some displays and on some OMRON products, often means
“word” and is abbreviated “Wd” in documentation in this sense.
The abbreviation “PC” means Programmable Controller and is not used as an abbreviation for anything else.
Visual Aids
The following headings appear in the left column of the manual to help you locate different types of
information.
Note Indicates
information of particular interest for ef
ficient and convenient operation
of the product.
1, 2, 3...
1. Indicates lists of one sort or another, such as procedures, checklists, etc.
OMRON, 1992
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of OMRON.
No patent liability is assumed with respect to the use of the information contained herein. Moreover, because OMRON is
constantly striving to improve its high-quality products, the information contained in this manual is subject to change
without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no
responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.
vi
TABLE OF CONTENTS
vii
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1
Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 Relay Circuits: The Roots of PC Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3 PC Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4 OMRON Product Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5 Overview of PC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6 Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7 Available Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2
Hardware Considerations . . . . . . . . . . . . . . . . . . . . . . . . .
2-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3 PC Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3
Memory Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2 Data Area Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3 Internal Relay (IR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4 Special Relay (SR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5 Data Memory (DM) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6 Holding Relay (HR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7 Timer/Counter (TC) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8 Temporary Relay (TR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4
Writing and Inputting the Program . . . . . . . . . . . . . . . . .
4-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2 Instruction Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3 The Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4 The Programming Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5 Preparation for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6 Inputting, Modifying, and Checking the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7 Controlling Bit Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8 Work Bits (Internal Relays) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9 Programming Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10 Program Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS
viii
SECTION 5
Instruction Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2 Notation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3 Instruction Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4 Data Areas, Definer Values, and Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5 Ladder Diagram Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6 Bit Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7 INTERLOCK and INTERLOCK CLEAR – IL(02) and ILC(03) . . . . . . . . . . . . . . . . . . .
5-8 JUMP and JUMP END – JMP(04) and JME(05) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9 END – END(01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10 NO OPERATION – NOP(00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11 Timer and Counter Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12 Data Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13 Data Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14 DATA COMPARE – CMP(20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15 Data Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16 BCD Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-17 Subroutines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18 Step Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-19 Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6
Program Execution Timing . . . . . . . . . . . . . . . . . . . . . . . .
6-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2 Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3 Calculating Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4 Instruction Execution Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5 I/O Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7
Program Debugging and Execution . . . . . . . . . . . . . . . . .
7-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2 Debugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3 Monitoring Operation and Modifying Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4 Program Backup and Restore Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2 Reading and Clearing Errors and Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4 Error Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendices
A Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B Programming Instructions and Execution Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C Programming Console Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D Error and Arithmetic Flag Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E Binary–Hexadecimal–Decimal Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F Word Assignment Recording Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G Program Coding Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ix
About this Manual:
The OMRON K-type Programmable Controllers offer an effective way to automate processing, manufacturing, assembly, packaging, and many other processes to save time and money. Distributed control systems can also be designed to allow centralized monitoring and supervision of several separate
controlled systems. Monitoring and supervising can be done through a host computer, connecting the
controlled system to a data bank. It is thus possible to have adjustments in system operation made
automatically to compensate for requirement changes.
The K-type Units can utilize a number of additional Units including dedicated Special I/O Units that
can be used for specific tasks and Link Units that can be used to build more highly integrated systems.
The K-types are equipped with large programming instruction sets, data areas, and other features to
control processing directly. Programming utilizes ladder-diagram programming methods, which are
described in detail for those unfamiliar with them.
This manual describes the characteristics and abilities of the K-types programming operations, instructions, and other aspects of operation and preparation that demand attention. Before attempting
to operate the PC, thoroughly familiarize yourself with the information contained herein. Hardware
information is provided in detail in the
Installation Guide
. A table of other manuals that can be used in
combination with this manual is provided at the end of
Section 1 Introduction
.
Section 1 Introduction
explains the background and some of the basic terms used in ladder-diagram programming. It also provides an overview of the process of programming and operating a PC
and explains basic terminology used with OMRON PCs. Descriptions of peripheral devices used with
the K-types and a table of other manuals available to use with this manual for special PC applications
are also provided.
Section 2 Hardware Considerations
explains basic aspects of the overall PC configuration and de-
scribes the indicators that are referred to in other sections of this manual.
Section 3 Memory Areas
takes a look at the way memory is divided and allocated and explains the
information provided there to aid in programming. It also explains how I/O is managed in memory and
how bits in memory correspond to specific I/O points.
Section 4 Programming
explains the basics of writing and inputting the ladder-diagram program,
looking at the elements that make up the ‘ladder’ part of a ladder-diagram program and explaining
how execution of this program is controlled and the methods required to input it input the PC. S
ec-
tion 5 Instruction Set
then goes on to describe individually all of the instructions used in program-
ming, while
Section 6 Program Execution Timing
explains the scanning process used to execute
the program and tells how to coordinate inputs and outputs so that they occur at the proper times.
Section 7 Debugging and Execution
provides the Programming Console procedures used to debug
the program and to monitor and control system operation.
Finally,
Section 8 Troubleshooting
provides information on system error indications and other
means of reducing system down time. Information in this section is also necessary when debugging a
program.
The
Appendices
provide tables of standard OMRON products available for the K-types, reference
tables of instructions and Programming Console operations, and other information helpful in PC operation.
WARNING Failure to read and understand the information provided in this manual may result in
personal injury or death, damage to the product, or product failure. Please read each
section
in its entirety and be sure you understand the information provided
in the section
and related sections before attempting any of the procedures or operations given.
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xi
PRECAUTIONS
This section provides general precautions for using the K-type Programmable Controllers (PCs) and related devices.
The
information contained in this section is important for the safe and r
eliable application of Pr
ogrammable Contr
ol-
lers. Y
ou must r
ead this section and understand the information contained
befor
e attempting to set up or operate a PC
system.
1 Intended
Audience
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
!
!
!
!
!
4Operating Environment Precautions
xii
1 Intended Audience
This
manual is intended for the following personnel, who must also have knowl
-
edge of electrical systems (an electrical engineer or the equivalent).
• Personnel in charge of installing FA systems.
• Personnel in charge of designing FA systems.
• Personnel in charge of managing FA systems and facilities.
2 General Precautions
The
user must operate the product according to the performance specifications
described in the operation manuals.
Before
using the product under conditions which are
not described in the manual
or applying the product to nuclear control systems, railroad systems, aviation
systems, vehicles, combustion systems, medical equipment, amusement machines, safety equipment, and other systems, machines, and equipment that
may
have a serious influence on lives and property if
used improperly
, consult
your OMRON representative.
Make sure that the ratings and performance characteristics of the product are
sufficient
for
the systems, machines, and equipment, and be sure to provide the
systems, machines, and equipment with double safety mechanisms.
This manual provides information for programming and operating the Unit. Be
sure
to read this manual before attempting to use the
Unit and keep this manual
close at hand for reference during operation.
WARNING It is extremely important that a PC and all PC Units be used for the specified
purpose
and under the specified conditions, especially in applications that can
directly or indirectly affect human life. You must consult with your OMRON
representative before applying a PC System to the above-mentioned
applications.
3 Safety Precautions
WARNING Do
not attempt to take any Unit apart while the power is being supplied. Doing
so
may result in electric shock.
WARNING Do not touch any of the terminals or terminal blocks while the power is being
supplied. Doing so may result in electric shock.
WARNING Do
not
attempt to disassemble, repair
, or modify any Units. Any attempt to do so
may result in malfunction, fire, or electric shock.
4 Operating Environment Precautions
Caution Do not operate the control system in the following locations:
• Locations subject to direct sunlight.
• Locations subject to temperatures or humidity outside the range specified in
the specifications.
• Locations
subject to condensation as the result of severe changes in tempera
-
ture.
!
!
!
!
5Application Precautions
xiii
• Locations subject to corrosive or flammable gases.
• Locations subject to dust (especially iron dust) or salts.
• Locations subject to exposure to water, oil, or chemicals.
• Locations subject to shock or vibration.
Caution Take
appropriate and suf
ficient countermeasures when installing systems in the
following locations:
• Locations subject to static electricity or other forms of noise.
• Locations subject to strong electromagnetic fields.
• Locations subject to possible exposure to radioactivity.
• Locations close to power supplies.
Caution The
operating environment of the PC
System can have a large ef
fect on the lon
-
gevity
and reliability of the system. Improper operating environments can lead to
malfunction,
failure, and other
unforeseeable problems with the PC System. Be
sure
that the operating environment is within the specified conditions at installa
-
tion and remains within the specified conditions during the life of the system.
5 Application Precautions
Observe the following precautions when using the PC System.
WARNING Always heed these precautions. Failure to abide by the following precautions
could lead to serious or possibly fatal injury.
• Always
ground the system to 100 Ω or less when installing the Units. Not con
-
necting to a ground of 100 Ω or less may result in electric shock.
• Always
turn OFF the power supply to the PC before attempting any of the fol
-
lowing.
Not turning OFF the power supply may result in malfunction or
electric
shock.
• Mounting
or dismounting I/O Units, CPU Units, Memory Cassettes, or any
other Units.
• Assembling the Units.
• Setting DIP switches or rotary switches.
• Connecting cables or wiring the system.
• Connecting or disconnecting the connectors.
Caution Failure
to abide by the following precautions could lead to faulty operation of the
PC
or the system, or
could damage the PC or PC Units. Always heed these pre
-
cautions.
• Fail-safe measures must be taken by the customer to ensure safety in the
event
of incorrect, missing, or abnormal signals caused by broken signal lines,
momentary power interruptions, or other causes.
• Interlock
circuits, limit circuits,
and similar safety measures in external circuits
(i.e.,
not in the Programmable Controller) must be provided by the customer
.
• Always
use the
power supply voltages specified in the operation manuals. An
incorrect voltage may result in malfunction or burning.
• Take
appropriate measures to ensure that the specified power with the rated
voltage
and frequency is supplied. Be particularly careful in places where the
power
supply is unstable. An incorrect power supply may result in malfunction.
• Install
external breakers and take other safety measures against short-circuit
-
ing
in external wiring. Insuf
ficient safety measures against short-circuiting may
result in burning.
5Application Precautions
xiv
• Do not apply voltages to the Input Units in excess of the rated input voltage.
Excess voltages may result in burning.
• Do not apply voltages or connect loads to the Output Units in excess of the
maximum
switching capacity
. Excess voltages or loads may result in
burning.
• Disconnect
the functional ground terminal when
performing withstand voltage
tests.
Not disconnecting the functional ground terminal may result in burning.
• Be sure that all the mounting screws, terminal screws, and cable connector
screws
are tightened to the torque specified in the
relevant manuals. Incorrect
tightening torque may result in malfunction.
• Leave
the label attached to
the Unit when wiring. Removing the label may re
-
sult in malfunction if foreign matter enters the Unit.
• Remove
the label after the completion of wiring to ensure proper heat dissipa
-
tion. Leaving the label attached may result in malfunction.
• Use
crimp terminals for wiring. Do not connect bare stranded wires directly to
terminals. Connection of bare stranded wires may result in burning.
• Wire all connections correctly.
• Double-check
all wiring and switch settings before turning ON the power sup
-
ply. Incorrect wiring may result in burning.
• Be
sure that the terminal blocks, Memory
Units, expansion cables, and other
items with locking devices are properly locked into place. Improper locking
may result in malfunction.
• Check
the user program for proper execution before actually running it on the
Unit. Not checking the program may result in an unexpected operation.
• Confirm
that no adverse ef
fect will occur in the system before attempting any of
the following. Not doing so may result in an unexpected operation.
• Changing the operating mode of the PC.
• Force-setting/force-resetting any bit in memory.
• Changing the present value of any word or any set value in memory.
• Resume
operation only after transferring to the new CPU Unit the contents of
the DM Area, HR Area, and other data required for resuming operation. Not
doing so may result in an unexpected operation.
• Do
not pull on the cables or bend the cables beyond their natural limit.
Doing
either of these may break the cables.
• Do
not place objects on top of the cables or other wiring lines. Doing so may
break the cables.
• When
replacing parts, be sure to confirm that the
rating of a new part is correct.
Not doing so may result in malfunction or burning.
• Before
touching a Unit, be sure to first touch a
grounded metallic object in order
to
discharge any
static built-up. Not doing so may result in malfunction or dam
-
age.
• Install the Units properly as specified in the operation manuals. Improper
installation of the Units may result in malfunction.
1
SECTION 1
Background
1-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 Relay Circuits: The Roots of PC Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3 PC Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4 OMRON Product Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5 Overview of PC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6 Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7 A
vailable Manuals
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1-1 Introduction
A Programmable Controller (PC) is basically a central processing unit (CPU)
containing a program and connected to input and output (I/O) devices (I/O
Devices). The program controls the PC so that when an input signal from an
input device turns ON, the appropriate response is made. The response normally involves turning ON an output signal to some sort of output device. The
input devices could be photoelectric sensors, pushbuttons on control panels,
limit switches, or any other device that can produce a signal that can be input
into the PC. The output devices could be solenoids, switches activating indicator lamps, relays turning on motors, or any other devices that can be activated by signals output from the PC.
For example, a sensor detecting a product passing by turns ON an input to
the PC. The PC responds by turning ON an output that activates a pusher
that pushes the product onto another conveyor for further processing. Another sensor, positioned higher than the first, turns ON a different input to
indicate that the product is too tall. The PC responds by turning on another
pusher positioned before the pusher mentioned above to push the too-tall
product into a rejection box.
Although this example involves only two inputs and two outputs, it is typical of
the type of control operation that PCs can achieve. Actually even this example is much more complex than it may at first appear because of the timing
that would be required, i.e., “How does the PC know when to activate each
pusher?” Much more complicated operations, however, are also possible.
The problem is how to get the desired control signals from available inputs at
appropriate times.
Desired control sequences are input to the K-type PCs using a form of PC
logic called ladder-diagram programming. This manual is written to explain
ladder-diagram programming and to prepare the reader to program and operate the K-type PCs.
1-2 Relay Circuits: The Roots of PC Logic
PCs historically originate in relay-based control systems. And although the
integrated circuits and internal logic of the PC have taken the place of the
discrete relays, timers, counters, and other such devices, actual PC operation proceeds as if those discrete devices were still in place. PC control, however, also provides computer capabilities and consistency to achieve a great
deal more flexibility and reliability than is possible with relays.
The symbols and other control concepts used to describe PC operation also
come from relay-based control and form the basis of the ladder-diagram programming method. Most of the terms used to describe these symbols and
concepts, however, originated as computer terminology.
The terminology used throughout this manual is somewhat different from relay terminology, but the concepts are the same. The following table shows
the relationship between relay terms and the PC terms used for OMRON
PCs.
Relay term PC equivalent
contact input or condition
coil output or work bit
NO relay normally open condition
NC relay normally closed condition
Relay vs. PC Terminology
Relay Circuits: The Roots of PC Logic Section 1-2
3
Actually there is not a total equivalence between these terms, because the
term condition is used only to describe ladder diagram programs in general
and is specifically equivalent to one of certain basic instructions. The terms
input and output are not used in programming per se, except in reference to
I/O bits that are assigned to input and output signals coming into and leaving
the PC. Normally open conditions and normally closed conditions are explained in
4-3 The Ladder Diagram
.
1-3 PC Terminology
Although also provided in the
Glossary
at the back of this manual, the following terms are crucial to understanding PC operation and are thus explained
here as well.
When we refer to the PC, we are generally talking about the CPU and all of
the Units directly controlled by it through the program. This does not include
the I/O devices connected to PC inputs and outputs.
If you are not familiar with the terms used above to describe a PC, refer to
Section 2 Hardware Considerations
for explanations.
A device connected to the PC that sends a signal to the PC is called an input
device; the signal it sends is called an input signal. A signal enters the PC
through terminals or through pins on a connector on a Unit. The place where
a signal enters the PC is called an input point. This input point is allocated a
location in memory that reflects its status, i.e., either ON or OFF. This memory location is called an input bit. The CPU in its normal processing cycle
monitors the status of all input points and turns ON and OFF corresponding
input bits accordingly.
There are also output bits in memory that are allocated to output points on
Units through which output signals are sent to output devices, i.e., an output bit is turned ON to send a signal to an output device through an output
point. The CPU periodically turns output points ON and OFF according to the
status of the output bits.
These terms are used when describing different aspects of PC operation.
When programming, one is concerned with what information is held in memory, and so I/O bits are referred to. When describing the Units that connect
the PC to the controlled system and the places on these Units where signals
enter and leave the PC, I/O points are referred to. When wiring these I/O
points, the physical counterparts of the I/O points, either terminals or connector pins, are referred to. When describing the signals that enter or leave the
system, reference is made to input signals and output signals, or sometimes
just inputs and outputs.
The Control System includes the PC and all I/O devices it uses to control an
external system. A sensor that provides information to achieve control is an
input device that is clearly part of the Control System. The controlled system
is the external system that is being controlled by the PC program through
these I/O devices. I/O devices can sometimes be considered part of the controlled system, e.g., a motor used to drive a conveyor belt.
1-4 OMRON Product Terminology
OMRON products are divided into several functional groups that have generic names.
Appendix A Standard Models
list products by these groups.
The term Unit is used to refer to all OMRON PC products, depending on the
context.
The largest group of OMRON products is I/O Units. I/O Units come in a variety of point quantities and specifications.
PC
Inputs and Outputs
Controlled System and
Control System
OMRON Product Terminology Section 1-4
4
Special I/O Units are dedicated Units that are designed to meet specific
needs. These include Analog Timer Units and Analog I/O Units.
Link Units are used to create Link Systems that link more than one PC or
link a single PC to remote I/O points. Link Units include I/O Link Units that
are used to connect K-type PCs to Remote I/O Systems controlled by a larger PC (e.g. C1000H) and Host Link Units.
Other product groups include Programming Devices and Peripheral De-
vices.
1-5 Overview of PC Operation
The following are the basic steps involved in programming and operating a
K-type PC. Assuming you have already purchased one or more of these
PCs, you must have a reasonable idea of the required information for steps
one and two, which are discussed briefly below. This manual is written to explain steps three through six, eight, and nine. The section(s) of this manual
that provide relevant information are listed with each of these steps.
1, 2, 3...
1. Determine what the controlled system must do, in what order, and at
what times.
2. Determine what Units will be required. Refer to the
Installation Guide
. If
a Link System is required, refer to the required
System Manual(s)
.
3. On paper, assign all input and output devices to I/O points on Units and
determine which I/O bits will be allocated to each. If the PC includes
Special I/O Units or Link Systems, refer to the individual
Operation
Manuals
or
System Manuals
for details on I/O bit allocation. (
Section 3
Memory Areas
)
4. Using relay ladder symbols, write a program that represents the se-
quence of required operations and their inter-relationships. Be sure to
also program appropriate responses for all possible emergency situations. (
Section 4 Writing and Inputting the Program, Section 5 Instruc-
tion Set
, and
Section 6 Program Execution Timing)
5. Input the program and all required operating parameters into the PC.
(
Section 4 Writing and Inputting the Program
)
6. Debug the program, first to eliminate any syntax errors and then to elim-
inate execution errors. (
Section 4 Writing and Inputting the Program,
Section 7 Program Debugging and Execution
, and
Section 8
T roubleshooting
)
7. Wire the PC to the controlled system. This step can actually be started
as soon as step 3 has been completed. Refer to the
Installation Guide
and to
Operation Manuals
and
System Manuals
for details on individual
Units.
8. Test the program in an actual control situation and fine tune it if required.
(
Section 7 Program Debugging and Execution
and
Section 8
T roubleshooting
)
9. Record two copies of the finished program on masters and store them
safely in different locations. (
Section 7 Program Debugging and Execu-
tion
)
Designing the Control System is the first step in automating any process. A
PC can be programmed and operated only after the overall Control System is
fully understood. Designing the Control System requires a thorough understanding of the system that is to be controlled. The first step in designing a
Control System is thus determining the requirements of the controlled system.
Control System Design
Overview of PC Operation Section 1-5
5
The first thing that must be assessed is the number of input and output points
that the controlled system will require. This is done by identifying each device
that is to send an input signal to the PC or which is to receive an output signal from the PC. Keep in mind that the number of I/O points available depends on the configuration of the PC. Refer to
3-3 Internal Relay (IR) Area
for details on I/O capacity and assigning I/O bits to I/O points.
Next, determine the sequence in which control operations are to occur and
the relative timing of the operations. Identify the physical relationships between the I/O devices as well as the kinds of responses that should occur
between them.
For instance, a photoelectric switch might be functionally tied to a motor by
way of a counter within the PC. When the PC receives an input from a start
switch, it could start the motor. The PC could then stop the motor when the
counter has received five input signals from the photoelectric switch.
Each of the related tasks must be similarly determined, throughout the entire
control operation.
The actual Units that will be mounted must be determined according to the
requirements of the I/O devices. This will include actual hardware specifications, such as voltage and current levels, as well as functional considerations, such as those that require Special I/O Units or Link Systems. In many
cases, Special I/O Units or Link Systems can greatly reduce the programming burden. Details on these Units and Link Systems are available in individual
Operation Manuals
and
System Manuals.
Once the entire Control System has been designed, the task of programming, debugging, and operation as described in the remaining sections of
this manual can begin.
1-6 Peripheral Devices
The following peripheral devices can be used in programming, either to input/
debug/monitor the PC program or to interface the PC to external devices to
output the program or memory area data. Model numbers for all devices
listed below are provided in
Appendix A Standard Models
. OMRON product
names have been placed in bold when introduced in the following descriptions.
A Programming Console is the simplest form of programming device for OMRON PCs. Although a Programming Console Adapter is sometimes required, all Programming Consoles are connected directly to the CPU without
requiring a separate interface. The Programming Console also functions as
an interface to output programs to a standard cassette tape recorder.
Various types of Programming Console are available, including both
CPU-mounting and Handheld models. Programming Console operations are
described later in this manual.
A
Peripheral Interface Unit is required to interface the GPC to the PC.
The GPC also functions as an interface to output programs directly to a standard cassette tape recorder
. A
PROM Writer, Floppy Disk Interface Unit, or
Printer Interface Unit can be directly mounted to the GPC to output pro-
grams directly to an EPROM chip, floppy disk drive, or printing device.
LSS is designed to run on IBM AT/XT compatibles to enable nearly all of the
operations available on the GPC. It also offers extensive documentation capabilities.
Input/Output Requirements
Sequence, Timing, and
Relationships
Unit Requirements
Programming Console
Graphic Programming
Console: GPC
Ladder Support Software:
LSS
Peripheral Devices Section 1-6
6
A Host Link Unit is required to interface a computer running LSS to the PC.
Using an Optical Host Link Unit also enables the use of optical fiber cable to
connect the FIT to the PC. Wired Host Link Units are available when desired.
(Although FIT does not have optical connectors, conversion to optical fiber
cable is possible by using Converting Link Adapters.)
The FIT is an OMRON computer with specially designed software that allows
you to perform all of the operations that are available with the GPC or LSS.
Programs can also be output directly to an EPROM chip, floppy disk drive, or
printing device without any additional interface units. The FIT has an EPROM
writer and two 3.5” floppy disk drives built in.
A
Peripheral Interface Unit or Host Link Unit is required to interface the
FIT to the PC. Using an Optical Host Link Unit also enables the use of optical
fiber cable to connect the FIT to the PC. Wired Host Link Units are available
when desired. (Although FIT does not have optical connectors, conversion to
optical fiber cable is possible by using Converting Link Adapters.)
Other than its applications described above, the PROM Writer can be
mounted to the PC’s CPU to write programs to EPROM chips.
Other than its applications described above, the Floppy Disk Interface Unit
can be mounted to the PC’s CPU to interface a floppy disk drive and write
programs onto floppy disks.
Other than its applications described above, the Printer Interface Unit can be
mounted to the PC’s CPU to interface a printer or X-Y plotter to print out programs in either mnemonic or ladder-diagram form.
1-7 Available Manuals
The following table lists other manuals that may be required to program and/
or operate the K-type PCs.
Operation Manuals
and/or
Operation Guides
are
also provided with individual Units and are required for wiring and other
specifications.
Name Cat. No. Contents
Installation Guide W147 Hardware specifications
Data Access Console Operation Guide W173 Procedures for monitoring and manipulating data.
GPC Operation Manual W84 Programming procedures for the GPC (Graphics
Programming Console)
FIT Operation Manual W150 Programming procedures for using the FIT (Factory Intelligent
Terminal
LSS Operation Manual W237 Programming procedures for using LSS (Ladder Support
Software)
Printer Interface Unit Operation Guide W107 Procedures for interfacing a PC to a printer
PROM Writer Operation Guide W155 Procedures for writing programs to EPROM chips
Floppy Disk Interface Unit Operation Guide W119 Procedures for interfacing a PC to a floppy disk drive
Optical Remote I/O System Manual W136 Information on building an Optical Remote I/O System to
enable remote I/O capability
Host Link System Manual W143 Information on building a Host Link System to manage PCs
from a ‘host’ computer
K-type Analog I/O Units Operation Guide W122 Hardware and software information on using Analog I/O Units
with the K-type PCs.
Factory Intelligent Terminal:
FIT
PROM Writer
Floppy Disk Interface Unit
Printer Interface Unit
Available Manuals Section 1-7
7
SECTION 2
Hardware Considerations
2-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3 PC Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
2-1 Introduction
This section provides information on hardware aspects of K-type PCs that
are relevant to programming and software operation. These include indicators on the CPU and basic PC configuration. This information is covered in
detail in the
Installation Guide
.
2-2 Indicators
CPU indicators provide visual information on the general operation of the PC.
Using the flags and other error indicators provided in the memory data areas,
although not a substitute for proper error programming, provides ready confirmation of proper operation.
CPU indicators are located on the front right hand side of the PC adjacent to
the I/O expansion slot and are described in the following table.
Indicator Function
POWER Lights when power is supplied to the CPU.
RUN Lights when the CPU is operating normally.
ERR Lights when an error is discovered in system error diagnosis
operations. When this indicator lights, the RUN indicator will go
off, CPU operation will be stopped, and all outputs from the PC
will be turned OFF.
ALARM Lights when an error is discovered in system error diagnosis
operations. PC operation will continue.
2-3 PC Configuration
The system must contain a K-type CPU and may additionally contain an Expansion I/O Unit, Special I/O Units and/or I/O Link Units.
The Expansion I/O Units are not a required part of the basic system and are
used to increase the number of I/O points available. Special I/O Units and I/O
Link Units are used to reduce programming complexity.
CPU Indicators
PC Configuration Section 2-3
9
SECTION 3
Memory Areas
3-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2 Data Area Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3 Internal Relay (IR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4 Special Relay (SR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4-1 Battery Alarm Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4-2 Cycle Time Error Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4-3
High-speed Drum Counter Reset
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4-4
Clock Pulse Bits
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4-5 Error Flag (ER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4-6 Step Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4-7
Always OFF
, Always ON Flags
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4-8 First Cycle Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4-9 Arithmetic Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5 Data Memory (DM) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6 Holding Relay (HR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7 Timer/Counter (TC) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8 Temporary Relay (TR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
3-1 Introduction
Various types of data are required to achieve effective and correct control. To
facilitate managing this data, the PC is provided with various
memory areas
for data, each of which performs a different function. The areas generally accessible by the user for use in programming are classified as data areas.
The other memory area is the Program Memory, where the user’s program is
actually stored.
This section describes these areas individually and provides information that
will be necessary to use them. The name, acronym, range, and function of
each area are summarized in the following table. All but the last one of these
are data areas. All memory areas are normally referred to by their acronyms.
Area Acronym Range Function
Internal Relay
area
IR Words: 00 to 18 (bits 00 to 07)
Bits:
0000 to 1807
Used to manage I/O points, control other bits,
timers, and counters, to temporarily store data.
Special Relay
area
SR Words: 18 (bits 08 to 15) and
19 (bits 00 to 07)
Bits:
1808 to 1907
Contains system clocks, flags, control bits, and
status information.
Data Memory
area
DM DM 00 to DM 63
(words only)
Used for internal data storage and manipulation.
Holding Relay
area
HR Words: HR 0 to HR 9
Bits: HR 000 to HR 915
Used to store data and to retain the data values
when the power to the PC is turned off.
Timer/Counter
area
TC TC 00 to TC 47 (TC numbers are
used to access other information)
Used to define timers and counters and to access
completion flags, PV, and SV for them.
Temporary Relay
area
TR TR 00 to TR 07 (bits only) Used to temporarily store execution conditions.
Program Memory UM UM: 1,194 words. Contains the program executed by the CPU.
When some bits and words in certain data areas are not used for their intended purpose, they can be used in programming as required to control
other bits. Words and bits available for use in this fashion are called work bits
and work words. Most, but not all, unused bits can be used as work bits.
Those that can be are specified by area in the remainder of this section. Actual application of work bits and work words is described in
Section 4 Writing
and Inputting the Program
.
Some data areas contain flags and/or control bits. Flags are bits that are
automatically turned ON and OFF to indicate status of one form or another.
Although some flags can be turned ON and OFF by the user, most flags can
be read only; they cannot be controlled directly.
Control bits are bits turned ON and OFF by the user to control specific aspects of operation. Any bit given a name using the word bit rather than the
word flag is a control bit, e.g., Restart Bits are control bits.
3-2 Data Area Structure
When designating a data area, the acronym for the area is always required
for any but the IR and SR areas. Although the acronyms for the IR and SR
areas are often given for clarity, they are not required and not input when
programming. Any data area designation without an acronym is assumed to
be in either the IR and SR area. Because IR and SR addresses run consecutively, the word or bit addresses are sufficient to differentiate these two areas.
An actual data location within any data area but the TC area is designated by
its address. The address designates the bit and/or word within the area
where the desired data is located. The TR area consists of individual bits
Work Bits and Words
Flags and Control Bits
Data Area Structure Section 3-2
11
used to store execution conditions at branching points in ladder diagrams.
The use of TR bits is described in
Section 4 Writing and Inputting the Pro-
gram.
The TC area consists of TC numbers, each of which is used for a spe-
cific timer or counter defined in the program. Refer to
3-7 Timer/Counter (TC)
Area
for more details on TC numbers and to
5-11 Timer and Counter Instruc-
tions
for information on actual application.
The rest of the data areas (i.e., the IR, SR, HR and DM areas) consist of
words, each of which consists of 16 bits numbered 00 through 15 from right
to left. IR words 00 and 01 are shown below with bit numbers. Here, the content of each word is shown as all zeros. Bit 00 is called the rightmost bit; bit
15, the leftmost bit.
Bit number 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00
IR word 00 0000000000000000
IR word 01 0000000000000000
The term least significant is often used for rightmost; the term most significant, for leftmost. These terms have not been used in this manual because a
single word is often split into two or more parts, with each part used for different parameters or operands, sometimes even with bits in another word.
When this is done, the rightmost bits in a word may actually be the most significant bits, i.e., the leftmost bits, of a value with other bits, i.e., the least significant bits, contained in another word.
The DM area is accessible by word only; you cannot designate an individual
bit within a DM word. Data in the IR, SR and HR areas is accessible either by
bit or by word, depending on the instruction in which the data is being used.
To designate one of these areas by word, all that is necessary is the acronym
(if required) and the one or two-digit word address. To designate an area by
bit, the word address is combined with the bit number as a single three- or
four-digit address. The examples in the following table should make this
clear. The two rightmost digits of a bit designation must indicate a bit between 00 and 15.
The same TC number can be used to designate either a word containing the
present value (PV) of the timer or counter or a bit that functions as the completion flag for the timer or counter. This is explained in more detail in
3-7
Timer/Counter (TC) Area
.
Area Word designation Bit designation
IR 00 0015 (leftmost bit in word 00)
SR 19 1900 (rightmost bit in word 19)
DM DM 10 Not possible
TC TC 46 (designates PV) TC 46 (designates completion flag)
Word data input as decimal values is stored in binary-coded decimal (BCD)
code; word data input as hexadecimal is stored in binary form. Because each
word contains 16 bits, each four bits of a word represents one digit: either a
hexadecimal digit equivalent numerically to the binary bits or decimal. One
word of data thus contains four digits, which are numbered from right to left.
These digit numbers and the corresponding bit numbers for one word are
shown below.
Bit number
Contents 0000000000000000
15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00
Digit number 3210
Note
Data Structure
Data Area Structure Section 3-2
12
When referring to the entire word, the digit numbered 0 is called the rightmost digit; the one numbered 3, the leftmost digit.
When inputting data into data areas, it must be input in the proper form for
the intended purpose. This is no problem when designating individual bits,
which are merely turned ON (equivalent to a binary value of 1) or OFF (a binary value of 0). When inputting word data, however, it is important to input it
either as decimal or as hexadecimal, depending on what is called for by the
instruction it is to be used for.
Section 5 Instruction Set
specifies when a par-
ticular form of data is required for an instruction.
Binary and hexadecimal can be easily converted back and forth because
each four bits of a binary number is numerically equivalent to one digit of a
hexadecimal number. The binary number 0101111101011111 is converted to
hexadecimal by considering each set of four bits in order from the right. Binary 1111 is hexadecimal F; binary 0101 is hexadecimal 5. The hexadecimal
equivalent would thus be 5F5F, or 24,415 in decimal (16
3
x 5 + 162 x 15 + 16
x 5 + 15).
Decimal and BCD can also be easily converted back and forth. In this case,
each BCD digit (i.e., each four BCD bits) is numerically equivalent of the corresponding decimal digit. The BCD bits 0101011101010111 are converted to
decimal by considering each four bits from the right. Binary 0101 is decimal
5; binary 0111 is decimal 7. The decimal equivalent would thus be 5,757.
Note that this is not the same numeric value as the hexadecimal equivalent
of 0101011101010111, which would be 5,757 hexadecimal, or 22,359 in decimal (16
3
x 5 + 162 x 7 + 16 x 5 + 7).
Because the numeric equivalent of each four BCD binary bits must be
equivalent to a decimal value, any four bit combination numerically greater
then 9 cannot be used, e.g., 1011 is not allowed because it is numerically
equivalent to 11, which cannot be expressed as a single digit in decimal notation. The binary bits 1011 are of course allowed in hexadecimal and they are
equivalent to the hexadecimal digit C.
There are instructions provided to convert data in either direction between
BCD and hexadecimal. Refer to
5-15 Data Conversion
for details. Tables of
binary equivalents to hexadecimal and BCD digits are provided in the appendices for reference.
Decimal points are used in timers only. The least significant digit represents
tenths of a second. All arithmetic instructions operate on integers only.
3-3 Internal Relay (IR) Area
The IR area is used both to control I/O points and as work bits to manipulate
and store data internally. It is accessible both by bit and by word. Those
words that can be used to control I/O points are called I/O words. Bits in I/O
words are called I/O bits.
The number of I/O words varies between the K-type PCs. As shown, the IR
area is comprised of three main sections. These are input words, output
words and work words (work bits). Work bits are used in programming to manipulate data and control other bits. IR area work bits are reset when power
is interrupted or PC operation is stopped.
Converting Different Forms
of Data
Decimal Points
Internal Relay (IR) Area Section 3-3
13
The maximum number of available I/O bits is 16 (bits/word) times the number
of I/O words. I/O bits are assigned to input or output points as described in
Word Allocations
.
If a Unit brings inputs into the PC, the bit assigned to it is an input bit; if the
Unit sends an output from the PC, the bit is an output bit. To turn on an output, the output bit assigned to it must be turned ON. When an input turns on,
the input bit assigned to it also turns ON. These facts can be used in the program to access input status and control output status through I/O bits.
I/O bits that are not assigned to I/O points can be used as work bits, unless
otherwise specified in
Word Allocations
.
Input bits can directly input external signals to the PC and can be used in any
order in programming. Each input bit can also be used in as many instructions as required to achieve effective and proper control. They cannot be
used in instructions that control bit status, e.g., the OUTPUT, DIFFERENTIATION UP, and KEEP instructions.
Output bits are used to output program execution results and can be used in
any order in programming. Because outputs are refreshed only once during
each cycle (i.e. once each time the program is executed), any output bit can
be used in only one instruction that controls its status, including OUT, OUT
NOT
, KEEP(1
1), DIFU(13), DIFD(14), and SFT(10). If an output bit is used in
more than one such instruction, only the status determined by the last instruction will actually be output from the PC. See
5-12-1 SHIFT REGISTER -
SFT(10)
for an example of an output bit controlled by two instructions.
The maximum number of words available for I/O within the IR area is 10,
numbered 00 through 09. The remaining words (10 through 18) are to be
used for work bits. (Note that with word 18, only the bits 00 through 07 are
available for work bits although some of the remaining bits are required for
special purposes when RDM is used).
The actual number of bits that can be used as I/O bits is determined by the
model of the CPU and the PC configuration. There are different models of
Expansion I/O Units and Special I/O Units and I/O Link Units which can be
connected to any of the CPUs. Each CPU model provides a particular number of I/O bits and each Expansion I/O Unit, Special I/O Unit or I/O Link Unit
provides a particular number of I/O bits. Configuration charts for the possible
combinations of CPUs and Units are included later in this section. Refer to
those to determine the actual available I/O bits.
Within CPUs the I/O input words are always even numbered and the output
words are always odd numbered. The general rule when connecting Expansion I/O Units to CPUs is that the first available word for the Expansion I/O
Unit (whether input or output or a combination) is one more than the last I/O
word of the CPU. If the Expansion I/O Unit is only either input or output (and
not both) then the I/O words provided by the Expansion I/O Unit are allocated
consecutively and the remaining words up to word 09 may be used for work
bits. If the Expansion I/O Unit provides both input and output words then the
words are allocated alternatively (input words always having even numbers)
until all I/O words provided by the Expansion I/O Unit are allocated. The remaining words up to word 09 may then be used for work bits. Note that when
a portion of an input word is not allocated to an input point then that portion
may be used for work bits.
I/O Words
Input Bit Usage
Output Bit Usage
Word Allocations
Internal Relay (IR) Area Section 3-3
14
The following table shows which bits can be used as I/O bits in each of the
K-type CPUs. Bits in the shaded areas can be used as work bits but not as
output bits.
08
09
10
11
12
13
14
15
Word 00
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word 01
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word 00
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word 01
C20K
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word 00
00
01
02
03
04
05
06
07
Word 02
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word 01
00
01
02
03
04
05
06
07
Word 03
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word 00
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word 02
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word 01
00
01
02
03
04
05
06
07
Word 03
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Model Input bits
Output bits
C28K
C40K
C60K
08
09
10
11
indicates
words that cannot be used for I/O,
but can be used as work bits.
Cannot
be
used.
Cannot
be
used.
I/O Bits Available in CPUs
Internal Relay (IR) Area Section 3-3
15
The following table shows which bits can be used as I/O bits in each of the
Expansion I/O Units. Bits in the shaded areas can be used as work bits but
not as output bits. The word addresses depend on the CPU that the Expansion I/O Unit is coupled to. In all cases the first Expansion I/O Unit address
for input and output words is one more than the last CPU address for input
and output words. For example, the last CPU word address for a C40K CPU
is 03 and hence the first input or output word address for any of the Expansion I/O Units coupled to a C40K CPU will be 04. In the tables below “n” is
the last CPU word allocated as an input or output word.
There are several models for some of the Units listed below. A blank space
(_) in the model number indicates that any of the applicable model numbers
could be inserted here.
08
09
10
11
12
13
14
15
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word (n+1)
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
00
01
02
03
04
05
06
07
Word (n + 2)
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
00
01
02
03
04
05
06
07
Word (n + 3)
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word (n + 2)
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
00
01
02
03
04
05
06
07
Word (n + 3)
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word (n + 1)
00
01
02
03
04
05
06
07
Word (n + 1)
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word (n + 1)
00
01
02
03
Word (n + 1)
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word (n + 2)
08
09
10
11
12
13
14
15
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Word (n + 1)
Model Input bits Output bits Model Input bits Output bits
C20P
C16P
-Ij-j
C28P
C40P
C60P
C16P
-Oj-j
C4K-Ij
C4K-Oj
C4K-TM
Cannot
be used
Word (n+1)
Word (n+1)
Word (n+1)
Word (n + 2)
Word (n + 2)
Word (n + 4)
Word (n + 4)
08
09
10
11
indicates
words that cannot be used for I/O,
but can be used as work bits.
00
01
02
03
Cannot
be used
Cannot
be
used.
Cannot
be
used.
I/O Bits Available in
Expansion I/O Units
Internal Relay (IR) Area Section 3-3
16
A K-type PC can be configured with a CPU Unit and one or more of the following Units: Expansion I/O Units, Analog Timer Units, or an I/O Link Unit. All
of these Units are connected in series with the CPU Unit at one end. An I/O
Link Unit, if included, must be on the other end (meaning only one I/O Link
Unit can be used) and an Analog Timer Unit cannot be used. The rest of the
Units can be in any order desired.
There is also a restriction in the number of Units which can be included. To
compute the number of Units for this restriction, add up all of the Units counting the C40K CPU Unit, C60K CPU Unit, C40K Expansion I/O Unit and C60K
Expansion I/O Unit as two Units each and any other Units as one Unit each.
This total must be no more than five.
The following table shows some of the combinations that can be used to
achieve specific numbers of I/O points. The numbers in the table indicate the
number of Units of that size to be used as either the CPU or Expansion I/O
Unit; any one of the Units can be the CPU Unit. This table does not include
the C4P or C16P Expansion I/O Units, the Analog Timer Unit, or the I/O Link
Unit, which can be used for greater system versatility or special applications.
Refer to the remaining tables in this section for other combinations.
I/O points Count as 2
each
Count as 1
each
Total In Out C60j
(32/28)
C40j
(24/16)
C28j
(16/12)
C20j
(12/8)
20 12 8 --- --- --- 1
28 16 12 --- --- 1 --40 24 16
--- --- --- 2
--- 1 --- --48 28 20 --- --- 1 1
56 32 24 --- --- 2 --60
32 28 1 --- --- --36 24
--- --- --- 3
--- 1 --- 1
68 40 28
--- --- 1 2
--- 1 1 --76 44 32 --- --- 2 1
80 48 32
--- --- --- 4
--- 1 --- 2
--- 2 --- ---
1 --- --- 2
84 48 36 --- --- 3 --88
48 40 1 --- 1 --52 36
--- --- 1 3
--- 1 1 1
96 56 40
--- --- 2 2
--- 1 2 ---
100 56 44
1 --- --- 2
1 1 --- ---
I/O points Count as 2
each
Count as 1
each
Total In Out C60j
(32/28)
C40j
(24/16)
C28j
(16/12)
C20j
(12/8)
100 60 40
--- --- --- 5
--- 1 --- 3
--- 2 --- 1
104 60 44 --- --- 3 1
108
60 48 1 --- 1 1
64 44
--- --- 1 4
--- 1 1 2
--- 2 1 ---
112 64 48 --- --- 4 --116
64 52 1 --- 2 --68 48
--- --- 2 3
--- 1 2 1
120
64 56 2 --- --- --68 52
1 --- --- 3
1 1 --- 1
124 72 52
--- --- 3 2
--- 1 3 --128 72 56
1 --- 1 2
1 1 1 --132 76 56 --- --- 4 1
136 76 60 1 --- 2 1
140
76 64 2 --- --- 1
80 60 --- --- 5 --144 80 64 1 --- 3 --148 80 68 2 --- 1 ---
PC Configuration
Internal Relay (IR) Area Section 3-3
17
The tables on the following pages show the possible configurations for a
K-type PC. Although the tables branch to show the various possibilities at
any one point, there can be no branching in the actual PC connections. You
can choose either branch at any point and go as far as required, i.e., you can
break off at any point to create a smaller PC System.When implementing a
system there is a physical restriction on the total cable length allowable. The
sum of the lengths of all cables in the system must be limited to less than 1.2
meters.
The tables also show which words will be input words and which words will
be output words. All of these are determined by the position of the Unit in the
configuration except for the C4P and C16P Expansion I/O Units, in which
case the model of the Unit determines whether the words are input or output.
The symbols used in the table represent the following:
C20K/C28K
Input Output
C40P/C60P
Input Output Input Output
C20P/C28P/TU/LU,
Input Output
C4K/C16P
In/Output
C40K/C60K
Input Output
Input Output
C20K or C28K CPU Unit
C40K or C60K CPU Unit
C4P or C16P Expansion I/O Unit
C20P Expansion I/O Unit, C28K Expansion I/O Unit,
Analog Timer Unit, or I/O Link Unit
C40P or C60P Expansion I/O Unit
Internal Relay (IR) Area Section 3-3
18
C20K/C28K
Input Output
C40P/C60P
Input Output Input Output
C20P/C28P/TU/LU
Input Output
C20P/C28P/TU/LU
Input Output
C20P/C28P/TU/LU
Input Output
C20P/C28P/TU/LU
Input Output
C20P/C28P/TU/LU
Input Output
C20P/C28P/TU/LU
Input Output
C20P/C28P/TU/LU
Input Output
C40P/C60P
Input Output Input Output
C40P/C60P
Input Output Input Output
C20P/C28P/TU/LU
Input Output
C20P/C28P/TU/LU
Input Output
C20P/C28P/TU/LU
Input Output
C20P/C28P/TU/LU
Input Output
C20P/C28P/TU/LU
Input Output
C40P/C60P
Input Output Input Output
C4K/C16P
In/Output
C4K/C16P
In/Output
C4K/C16P
In/Output
C4K/C16P
In/Output
C4K/C16P
In/Output
C4K/C16P
In/Output
C4K/C16P
In/Output
C4K/C16P
In/Output
C4K/C16P
In/Output
C4K/C16P
In/Output
C4K/C16P
In/Output
C4K/C16P
In/Output
C4K/C16P
In/Output
IR
00
IR 01 IR 02 IR 03 IR 04 IR 05 IR 06 IR 07 IR 08 IR 09
Internal Relay (IR) Area Section 3-3
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